Protection for implanted gold surfaces

ABSTRACT

An implantable device includes an exterior gold surface and a thin film disposed on the exterior gold surface and forming a barrier between the exterior gold surface and an implanted environment, in which the thin film includes molecules with a head portion, the head portion attached to the exterior gold surface.

RELATED DOCUMENTS

The present application is a continuation and claims the benefit under35 U.S.C. § 119(e) of U.S. application Ser. No. 13/993,019, entitled“Protection for Implanted Gold Surfaces” filed Jun. 10, 2013 whichclaims the benefit under 35 U.S.C. § 371 to International PCTapplication No.: PCT/US2011/064853 filed Dec. 14, 2011 which claims thebenefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No.61/423,320, entitled “Protection for Implanted Gold Surfaces” filed Dec.15, 2010, which applications are incorporated herein by reference intheir entirety.

BACKGROUND

Hermetically sealed cases can be used to isolate electronic devices fromenvironmental contamination. To form electrical connections between theinterior and the exterior of a hermetically sealed case, a hermeticfeedthrough can be used. This hermetic feedthrough maintains theintegrity of the hermetic sealed case, while allowing electrical signalsto pass through. The sealed case and hermetic feedthrough may have anumber of gold surfaces. For example, gold braze joints can be used toseal electrically conductive pins into the feedthrough or to seal thefeedthrough into an aperture in the hermetic case. Gold is a relativelyinert element and resists many types of chemical corrosion. However, inimplanted environments gold can corrode, particularly when subjected tohigh electrical current densities.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate various embodiments of theprinciples described herein and are a part of the specification. Theillustrated embodiments are merely examples and do not limit the scopeof the claims.

FIG. 1 is an exploded view of an illustrative hermetically sealed case,according to one example of principles described herein.

FIG. 2A is a cross-sectional view of an illustrative electricalfeedthrough that includes conductive pins that are hermetically sealedinto a ceramic body using a gold braze joint, according to one exampleof principles described herein.

FIG. 2B is a perspective view of the illustrative electrical feedthroughshown in FIG. 2A, according to one example of principles describedherein.

FIG. 3A is a cross-sectional view of an illustrative electricalfeedthrough that is joined to a case using a gold braze joint, accordingto one example of principles described herein.

FIG. 3B is a cut-away perspective view of the illustrative electricalfeedthrough shown in FIG. 3A, according to one example of principlesdescribed herein.

FIGS. 4A-4E are diagrams showing illustrative surface treatments forprotecting implanted gold surfaces, according to one example ofprinciples described herein.

FIG. 5 is a flowchart showing an illustrative method for creatingsurface treatments for protecting implanted gold braze joints, accordingto one example of principles described herein.

Throughout the drawings, identical reference numbers designate similar,but not necessarily identical, elements.

DETAILED DESCRIPTION

Human implant technologies often make use of hermetically sealeddevices. The hermetically sealed devices are substantially impermeableto liquids and gasses and prevent body fluids from damaging electroniccomponents contained within the device. In an implanted environment, thehermetically sealed case is subject to a variety of corrosive chemicalsand mechanical forces. However, the implanted case must be highlyreliable over the lifetime of the biomedical device.

As mentioned above, a feedthrough is often used to form an electrical orphysical connection between the interior and the exterior of a sealedcase. An electrical feedthrough maintains the integrity of thehermetically sealed case, while allowing electrical signals to passthrough. The electrical feedthrough is often constructed as a separateelement and then sealed into an aperture in a wall of the case. Avariety of gold elements can be incorporated into the hermiticallysealed device and feedthrough. For example, gold elements can beincorporated as pins, coatings, joints, or other components. Forexample, it can be desirable to use a gold brazing process as a means ofjoining components of the feedthrough and/or joining the electricalfeedthrough to the implant housing. Gold brazing is a well understoodprocess that is used in a large number of active biomedical implants.Further, gold is a relatively inert element and resists many types ofchemical corrosion. However, some implant devices, such as cochlearimplants, pass relatively high currents through and around the goldjoints. As current densities increase, the susceptibility of the goldjoint to chemical corrosion also increases. Where a gold joint is usedto seal conductive pins into an electrical feedthrough, the gold jointis part of the current path. Where a gold joint is used to seal theelectrical feedthrough to the case, the gold joint may be part of thegrounding path for the device. The resulting current densities andvoltage potentials may lead to increased surface corrosion of the gold.

In the following description, for purposes of explanation, numerousspecific details are set forth in order to provide a thoroughunderstanding of the present systems and methods. It will be apparent,however, to one skilled in the art that the present apparatus, systems,and methods may be practiced without these specific details. Referencein the specification to “an embodiment,” “an example,” or similarlanguage means that a particular feature, structure, or characteristicdescribed in connection with the embodiment or example is included in atleast that one embodiment, but not necessarily in other embodiments. Thevarious instances of the phrase “in one embodiment” or similar phrasesin various places in the specification are not necessarily all referringto the same embodiment.

As used in the specification and appended claims, the term “pin” refersto an electrically conductive channel between the exterior and interiorof a hermetic feedthrough. A pin may have a wide variety of shapesincluding circular, square, rectangular, elliptical, irregular, or othershapes. Further, in some examples such as co-axial feedthroughs, pinsmay be nested within other pins. As used in the specification andappended claims, the term “thin film” is used broadly to refer to filmsranging from fractions of a nanometer (a monolayer) to microns inthickness.

FIG. 1 is an exploded view of an illustrative hermetic enclosure (100)that houses cochlear implant electronics. In this particular example,the hermetic enclosure (100) includes a case (110) and a case top (115).The case (110) and the case top (115) may be formed from a variety ofbiocompatible materials. For example, the case (110) and case top (115)may be formed from metals, ceramics, crystalline structures, composites,or other suitable materials. The outer case (110) may be formed from asingle piece of material or may include multiple pieces. The multiplepieces may be connected using a variety of techniques including, but notlimited to, brazing, laser welding, or bonding.

According to one illustrative example, the case (110) and the case top(115) are formed from titanium. The case (110) shown in FIG. 4A is aclosed-bottom cylinder that is machined, stamped, or otherwise formedfrom a single piece of titanium. In this example, the case (110)includes two apertures (111, 112) that are configured to receivehermetic electrical feedthroughs (101, 120). The case top (115) is alsomade from titanium and can be placed onto a ledge (116) machined intothe upper rim of the case (110). The case top (115) can then be laserwelded or brazed onto the case (110). Once the case top (115) andhermetic electrical feedthroughs (101, 120) are in place, the hermeticenclosure (100) prevents liquids or gasses from entering the interior ofthe enclosure (100). As discussed above, this prevents damage toelectronics or other components housed in the interior of the hermeticenclosure (100).

The electrical feedthroughs (101, 120) may be formed from a variety ofmaterials and have a number of different configurations. According toone illustrative example, the electrical feedthroughs (101, 120) includea set of conductors (108, 109) that are imbedded in ceramic bodies (104,105). The conductors (108, 109) pass through and are sealed in theceramic body. The sealing of the conductors to the ceramic body may takeplace in a variety of ways, including gold brazing or partiallytransient liquid phase (pTLP) bonding.

The ceramic body (104, 105) is then joined to the appropriate aperture(111, 112) in the case (110). A variety of techniques, including goldbraze joints can be used to join the ceramic body to the case (110). Inthis illustrative example, the hermetic feedthroughs (101, 120) are onthe perimeter of the case (110). The hermetic feedthroughs (101, 120)are well protected by the case (110) to minimize damage from impactloads. Although the feedthroughs (101, 120) are illustrated as beinglocated in the perimeter of the case (110) in this example, thefeedthroughs could also be located at other sites on the case (110) orthe case top (115). Further, the number and size of hermeticfeedthroughs (101,120) could be varied according to the designrequirements. For example, a single feedthrough could be used to accessall electrical connections to the internal electronics.

FIGS. 2A and 23 illustrate a feedthrough (101) that includes cylindricalpins (200) that are sealed into the ceramic body (104) using a goldbraze joint (202). FIG. 2A is a cross-sectional view of a portion of thecase (110) that includes the feedthrough (101). The left side of the pin(200) is connected to components that are internal to the case (110) andthe right side of the pin (200) is connected to components that areexternal to the case (110). As discussed above, the pin may have avariety of geometries and may be formed from a variety of materials. Inthis example, the pins (200) are cylindrical and may be formed fromplatinum or a platinum alloy such as platinum iridium. The right handsurface (205) of the gold braze joint (202) is on the external side ofthe hermetic case (100, FIG. 1) and can be corroded by exposure tobodily fluids.

FIG. 2B is a perspective view of a portion of the hermetic case (110)that includes part of the hermetic feedthrough (101). As discussedabove, the ceramic body (104) surrounds the pins (200), which are sealedwith a gold joint (202). As discussed above, the gold braze joint (202,FIG. 2A) in this example becomes part of the conductive pathway throughthe feedthrough (101). Consequently, a significant amount of electricalcurrent may pass through the gold braze joint (202, FIG. 2A).Additionally, the gold braze joint (202, FIG. 2A) also may have anelectrical voltage potential that is significantly different than thesurrounding body tissues. As a result, the exterior surface (205) of thegold braze joint may have a tendency to corrode when in contact withbody fluids and tissues.

The braze joint (202) may be formed in a variety of ways. For example,the gold braze joint (202) may be formed by placing the platinum pinsthrough holes in a fully densified ceramic body (104). The platinum pins(200) and ceramic body (104) are heated, and melted gold or a gold alloyis drawn by capillary action into the gap between the platinum pin (200)and the ceramic body (104).

In an alternative example, two layers of green ceramic tape are used toform the ceramic body. The pins (200) are coated with a layer of goldaround their circumference and laid on a bottom layer of green ceramictape. An upper layer of green ceramic tape is laid over the pins (200)and the bottom Layer. This sandwiches the gold coated pins (200) betweentwo layers of ceramic tape. The green ceramic tape is then densified bythe application of heat and pressure. The upper and lower ceramic layersare joined to form the ceramic body (104), and the gold forms a sealbetween the ceramic body (104) and the pins (200).

A variety of additional steps and alternative methods can be used toform the gold braze joint (202). For example, a number of cleaning stepsmay be employed to ensure a satisfactory bond between the gold, ceramic,and platinum. Flux and surface coatings could also be used. The goldcould be alloyed with a number of other elements, including platinum,nickel, titanium, palladium, iridium, or copper. In some examples, thecreation of the gold braze joint could incorporate principles used inactive metal brazing or include filler material.

The ceramic body (102) can be joined to the case (110) in a number ofways, including brazing, active metal brazing, ceramic/glass/metaljoining, transient liquid phase bonding, or other suitable techniques.

FIGS. 3A and 3B are diagrams of an illustrative feedthrough (101) thatis joined to a case (110) using a gold braze joint (210). FIG. 3A is across-sectional diagram of the hermetic case (110) and feedthrough(101). This figure shows ribbon vias (300) passing through the ceramicbody (104) and extending from both sides of the ceramic body (104). Thebraze joint (210) seals the ceramic body (104) to the case (110). Asdiscussed above, the case (110) may be formed from any biocompatiblematerial that has the desired impermeability and mechanicalcharacteristics. For example, titanium may be used to form the case.Titanium has a number of desirable characteristics, including highstrength, resiliency, biocompatibility, low density, and lowpermeability.

The ceramic body (104) may be formed from a variety of materials. Forexample, the ceramic body (104) may be formed from alumina. The ribbonvias (300) may also be formed from a range of materials that have thedesired characteristics. For example, the ribbon vias (300) may beformed from platinum or platinum alloy. Platinum has a number ofdesirable characteristics, including a relatively low electricalresistance, high malleability, biocompatibility, and ability to bealloyed with a number of other elements. In other examples, the ribbonvias (300) may be gold plated or formed from gold or gold alloy.

In this illustrative example, the ribbon vias (300) could be sealed intothe ceramic body (102) using partially transient liquid phase (pTLP)bonding. A number of methods and feedthroughs that use platinum ribbonvias sealed into a ceramic body using pTLP bonding are described in U.S.patent application Ser. No. 12/836,831 entitled “Electrical FeedthroughAssembly,” to Kurt J. Koester, filed on Jul. 15, 2010, which isincorporated herein by reference in its entirety.

The gold braze joint (210) is electrically insulated from the ribbonvies (300) and consequently does not directly conduct electricitythrough the feedthrough. However, the titanium case (110) may form theground plane for the device. Because the gold braze joint (210) is indirect electrical contact with the titanium case, the gold braze joint(210) is also subjected to the currents and voltages associated with thegrounding of the device. As discussed above, the surface portions of thegold braze joint (210) that are on the exterior of the device areexposed to bodily fluids and may be susceptible to corrosion.

Illustrative examples of two gold braze joints used in an electricalfeedthrough are given above. These are only illustrative examples andare not meant to be limiting. A variety of other gold elements couldhave exterior gold surfaces. For example, the conductive pins that passthrough the ceramic may be formed from gold or may be gold coated.Wires, connectors, pads, ball bonds, or other elements could also beformed from gold and have exterior gold surfaces that may also benefitfrom the surface protection afforded by the thin film techniquesdescribed below. The techniques described below are not limited toimplanted devices, but can be used in a variety of other applications aswell. For example, gold braze joints can be used in aerospace,industrial, microfluidics, medical equipment, and other applications.

FIGS. 4A-4E show a number of illustrative surface treatments that can beused to protect an exterior gold surface (402) of an implanted devicefrom the implanted environment. As discussed above, the exterior goldsurface (402) may be any surface that is exposed to the implantedenvironment. For example, the exterior gold surface may be a surface ofa braze joint, gold pin, gold plated platinum pin, tape automated bond,a ball bond, a weld joint, a surface plating, or other component of thehermetic device.

FIG. 4A shows a gold body (400) with a exterior gold surface (402). Asshown by FIGS. 4B-4E, this surface (402) is prepared and treated with athin film (404). FIG. 4B shows a thin film (404) that is composed of anumber of molecules that are attached to the exterior gold surface(402). In this example, each molecule in the thin film (404) includestwo functional groups: a first functional group that bonds to the goldsurface and a second functional group that extends away from the goldsurface. For example, the first functional group may include a sulfurmolecule, designated the “S” in FIG. 4B. Sulfur and sulfur containingmolecules may have a number of advantages, including forming strongbonds with gold and with a variety of other functional groups or organicmolecules. The bond between sulfur and gold is relatively strong, with abond energy of greater than 400 kJ/mol.

Examples of the thin film (404) include organosulfur compounds thatcontain a sulfur-hydrogen bond. A functional group “X” attaches to anappropriate chemical background illustrated by the thiol molecule “R”.Reaction by-products are not shown. The functional group “X” can beselected to attach to a variety of molecules, including pottingmaterials, silicone, silicon, or other molecules.

FIG. 40 shows the molecule “R” that is attached to a sol gel to form aglass (406). The glass (406) is shown as interconnected silicon andoxygen atoms. The glass is substantially impervious to chemical attackand protects the underlying gold surface (402) from corrosion by forminga barrier between the gold surface (402) and the implanted environment.

FIG. 4D shows an alternative example in which the functional group “X”is attached to a hydrophobic agent (406) that prevents fluids and watersoluble chemicals from contacting the gold surface (402). For example,these hydrophobic molecules may include silicone. In other examples, thefunctional group may be an epoxide or polyamine that bonds to componentswithin an epoxy potting agent. For example, the functional group may bea phenolic, aliphatic or polyamine molecule.

In this example, all molecules are identical; however, a variety ofdifferent molecules may be attached to the same gold surface to achievethe desired protection of the surfaces. Further, each molecule mayterminate in more than one functional group that bonds with overlyingmaterial.

FIG. 4E shows an entanglement coupling agent (410) directly attached tothe exterior gold surface (402). In this example, the entanglementcoupling agent (410) is long chain that is functionalized on one end.This functionalized end attaches to the exterior gold surface (402). Thetail portion of the entanglement coupling agent (410) then extends intothe potting material and is entangled with molecules in the pottingmaterial. This provides for more secure attachment of a potting material(412). The potting material (412) may be a variety of materialsincluding medical grade silicone. This strongly adhered

FIGS. 4A-4E are illustrative schematic representations of molecularconfigurations that could be used. The actual molecular configurationsof these coatings may be less regular than illustrated in FIGS. 4A-4E.For example, FIG. 4C shows uniform and symmetrical attachments betweenmolecules, which may or may not be realized in any given actualimplementation.

Each of FIGS. 4C through 4E represents water impermeable barriers thatprevent penetration of water for a long period of time. As used in thespecification and appended claims, the term “water impermeable barrier”is used to describe barriers that prevent medically significant amountsof liquid water, water vapor, or aqueous solutions from penetrating thebarrier in an implanted environment for a period of at least 30 days.For example, a water impermeable barrier may prevent substantial contactbetween aqueous solutions present in the implanted environment fromcontacting the underlying gold surface for a period of one year orlonger.

FIG. 5 is an illustrative method for surface modification of exteriorgold surfaces of implantable devices. The exterior gold surface isformed on the implanted device (step 500). As discussed above, theexterior gold surface may be a coating, joint, pin, wire, or othercomponent of the implanted device. For example, the exterior goldsurface can be a gold braze joint that acts as a structural seal betweenthe feedthrough body and an aperture or a structural seal between ahermetic feedthrough body and conductive pins. The exterior gold surfaceis then cleaned and prepared (step 505). For example, various etchingsolutions and/or mechanical abrasion may be used to remove anycontaminates from the surface of gold braze joint. The thin film isapplied to the prepared surface (step 510). As discussed above, the thinfilm molecules may have a head portion that has an affinity for the goldsurface and a tail portion that terminates in a functional group.

In one example, the thin film may be a self assembled monolayer (SAM).The SAM is created by the chemisorption of the head portions onto thegold surface from either a vapor or liquid. The tail portions, whichinclude a coupling agent, are then organized. The SAM molecules arebrought into contact with the gold surface and become closely assembledin an orderly monolayer array. In some examples, the SAMs may be analkanethiol. For example, the head portion designed to attach to a goldsurface may be an organosulfur. The sulfur has a strong affinity for thegold surface.

The coupling agent in the tail portion may be a long entangling moleculeor a functionalized molecule. For example, the tail may be made of analkyl chain with a terminal end that is functionalized. Thisfunctionalization may be achieved by adding —OH, —NH₃, —COOH, or othergroups at the terminal end of the tail. The functional groups can beselected to achieve the desired wetting and interfacial properties.

A overlying layer is attached to thin film (step 515). In oneimplementation, the overlying layer may be formed from protectivemolecules attached to the functional group of the thin film molecules.As discussed above, the protective molecules may be any of a number ofmolecules, including sol gels, molecules that alter the hydrophobicand/or lipophobic character of the surface, molecules that prevent fluidand vapor contact with the gold surface, entanglement molecules thatinterlock with potting materials, or other suitable molecules thatprotect the gold surface from corrosion. In some examples, a combinationof protective molecules with different types may be combined to provideincreased surface protection.

In sum, gold surfaces may be protected from corrosion in a chemicallyactive environment using a thin film coating. The properties of thesethin film coatings can be tuned to create a glass layer, entanglepotting material, adjust the wetting characteristics of the gold, createa barrier that prevents fluid and vapor contact with the exterior goldsurface, and produce other desirable surface modifications.

The preceding description has been presented only to illustrate anddescribe embodiments and examples of the principles described. Thisdescription is not intended to be exhaustive or to limit theseprinciples to any precise form disclosed. Many modifications andvariations are possible in light of the above teaching.

What is claimed is:
 1. An implantable device comprising: a gold body with an exterior gold surface, wherein the gold body forms a portion of a hermetic enclosure of the implantable device; a thin film disposed on the exterior gold surface, the thin film including an organosulfur compound, wherein the organosulfur compound comprises: a sulfur head attached to the exterior gold surface; and a tail; and an overlying material attached to the exterior gold surface by multiple molecules of the organosulfur compound, wherein the thin film and the overlying material protect the gold surface from corrosion and the tail is attached to the overlying material by entanglement.
 2. The implantable device of claim 1, wherein the overlying material comprises an epoxy.
 3. The implantable device of claim 1, wherein organosulfur compound comprises a thiol.
 4. The implantable device of claim 1, wherein the overlying material comprises a silicone.
 5. The implantable device of claim 1, wherein the tail comprises an alkyl chain entangled in the overlying material.
 6. The implantable device of claim 1, wherein the thin film comprises a self-assembled monolayer.
 7. The implantable device of claim 1, wherein the gold body is a braze joint that forms a hermetic seal between a first element and a second element of the implant device.
 8. The implantable device of claim 7, wherein the first element comprises a ceramic feedthrough and the second element comprises a titanium housing and wherein the overlying material covers the gold body and the overlying material does not cover the titanium housing.
 9. The implantable device of claim 7, wherein the first element comprises a ceramic feedthrough and the second element comprises a conductive pin passing through the ceramic feedthrough.
 10. An implantable device comprising: a gold body with an exterior gold surface, wherein the gold body forms a portion of a hermetic enclosure of the implantable device; and a thin film disposed on the exterior gold surface, the thin film including an organosulfur compound, wherein the organosulfur compound comprises: a head with a sulfur molecule attached to the exterior gold surface; and a tail; and an overlying material attached to the tail by entanglement between the tail and the overlying material.
 11. A method of forming a medical implant, the method comprising: forming a gold braze between a ceramic feedthrough and a metal component, wherein the gold braze, the metal component, and the ceramic feedthrough all form parts of a hermetic enclosure of an implantable medical device; applying organosulfur molecules to an exterior surface of the gold braze such that sulfur atoms of the organosulfur molecules are concentrated at the exterior surface of the gold braze; and applying an overlying material over the organosulfur molecules wherein the overlying material entangles with the organosulfur molecules.
 12. The method of claim 11 wherein the metal component is a titanium housing.
 13. The method of claim 11, wherein the metal component is a conductor pin.
 14. The method of claim 11, wherein the metal component is not gold and the gold braze and the metal component form a galvanic couple.
 15. The method of claim 11, wherein the organosulfur molecules are alkylthiols and the organosulfur molecules form a self-assembled monolayer (SAM) on the surface of the gold braze. 